FILE DETAILS:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200-7, PC200LC-7, PC220-7, PC220LC-7
Serial Number: 200001 and up, 60001 and up
Book Code: SEBM024314
Language: English
Pages: 840
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
COVER................................................................................................................................. 1 CONTENTS.............................................................................................................................. 2 01 GENERAL............................................................................................................................ 36 SPECIFICATION DIMENSION DRAWINGS ................................................................................................. 37 PC200-7, PC200LC-7............................................................................................................ 37 PC220-7, PC220LC-7............................................................................................................ 39 SPECIFICATIONS.................................................................................................................... 41 PC200-7, PC200LC-7............................................................................................................ 41 PC220-7, PC220LC-7............................................................................................................ 43 WEIGHT TABLE...................................................................................................................... 45 PC200-7, PC200LC-7............................................................................................................ 45 PC220-7, PC220LC-7............................................................................................................ 47 FUEL, COOLANT, AND LUBRICANTS..................................................................................................... 49 10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD...................................................................................... 50 ENGINE RELATED PARTS.............................................................................................................. 51 RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................... 52 POWER TRAIN....................................................................................................................... 53 FINAL DRIVE....................................................................................................................... 54 SWING MACHINERY................................................................................................................... 56 PC200-7, PC200LC-7............................................................................................................ 56 PC220-7, PC220LC-7............................................................................................................ 58 SWING CIRCLE...................................................................................................................... 60 PC200-7, PC200LC-7............................................................................................................ 60 PC220-7, PC220LC-7............................................................................................................ 61 TRACK FRAME・RECOIL SPRING......................................................................................................... 62 IDLER............................................................................................................................. 64 CARRIER ROLLER.................................................................................................................... 66 TRACK ROLLER...................................................................................................................... 67 TRACK SHOE........................................................................................................................ 68 HYDRAULIC EQUIPMENT LAYOUT DRAWING................................................................................................ 72 HYDRAULIC TANK.................................................................................................................... 74 HYDRAULIC PUMP.................................................................................................................... 75 CONTROL VALVE..................................................................................................................... 96 PC200-7, PC200LC-7............................................................................................................ 96 PC220-7, PC220LC-7............................................................................................................109 CLSS..............................................................................................................................125 SELF PRESSURE REDUCING VALVE......................................................................................................128 SWING MOTOR.......................................................................................................................131 REVERSE PREVENTION VALVE..........................................................................................................136 CENTER SWIVEL JOINT...............................................................................................................138 TRAVEL MOTOR......................................................................................................................139 TRAVEL JUNCTION VALVE.............................................................................................................148 STROKE REGULATION WHEN TRAVELLING.................................................................................................150 VALVE CONTROL.....................................................................................................................152 WORK EQUIPMENT・SWING PPC VALVE....................................................................................................153 TRAVEL PPC VALVE..................................................................................................................157 SERVICE PPC VALVE.................................................................................................................166 SOLENOID VALVE....................................................................................................................169 PPC ACCUMULATOR...................................................................................................................171 RETURN OIL FILTER ................................................................................................................172 BOOM HYDRAULIC DRIFT PREVENTION VALVE.............................................................................................173 LIFT CHECK VALVE..................................................................................................................176 ATTACHMENT CIRCUIT SELECTOR VALVE.................................................................................................177 HYDRAULIC CYLINDER................................................................................................................179 PC200-7, PC200LC-7............................................................................................................179 PC220-7, PC220LC-7............................................................................................................181 WORK EQUIPMENT....................................................................................................................183 AIR CONDITIONER...................................................................................................................190 ENGINE CONTROL....................................................................................................................191 ELECTRONIC CONTROL SYSTEM ........................................................................................................197 MULTI MONITOR SYSTEM..............................................................................................................221 7-SEGMENT MONITOR SYSTEM..........................................................................................................241 SENSOR............................................................................................................................248 20 TESTING AND ADJUSTING..............................................................................................................251 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....................................................................................252 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....................................................................................254 TESTING AND ADJUSTING.............................................................................................................269 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................................270 INSPECTION AND ADJUSTING OF ENGINE RPM........................................................................................272 MEASUREMENT OF EXHAUST GAS COLOR..............................................................................................274 ADJUSTMENT OF VALVE CLEARANCE.................................................................................................275 MEASUREMENT OF COMPRESSION PRESSURE...........................................................................................277 MEASUREMENT OF BLOW-BY PRESSURE...............................................................................................278 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING............................................................................279 MEASUREMENT OF ENGINE OIL PRESSURE............................................................................................281 ADJUSTMENT OF ENGINE SPEED SENSOR.............................................................................................282 INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION......................................................................282 EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM.........................................................................283 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.............................................................................284 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...............................................................................285 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL.................286 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.....................................................................290 INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE.............................................................291 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE.............................................................294 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.................................................................................299 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE......................................................................................302 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE..............................................................................303 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................304 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................305 MEASUREMENT OF OIL LEAKAGE AMOUNT.............................................................................................306 AIR BLEEDING OF VARIOUS PARTS.................................................................................................308 INSPECTION PROCEDURES FOR DIODE...............................................................................................310 SPECIAL FUNCTION OF MULTI-MONITOR PANEL.......................................................................................311 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL.................................................................................336 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM............................................................................353 TROUBLESHOOTING...................................................................................................................363 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................364 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................365 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................366 CHECKS BEFORE TROUBLESHOOTING ................................................................................................374 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..................................................................................375 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.............................................................379 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................417 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.......................................................................................454 BEFORE TROUBLESHOOTING FOR DISPLAYED CODE.....................................................................................457 TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED......................464 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................466 SERVICE CODE IN ELECTRICAL SYSTEM [E101] (ABNORMAL DATA IN ERROR HISTORY).................................................468 SERVICE CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....470 SERVICE CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....472 SERVICE CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................474 SERVICE CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...............................................478 SERVICE CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................480 SERVICE CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................482 SERVICE CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................486 SERVICE CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE / DIVIDE SOLENOID)....................................490 SERVICE CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................494 SERVICE CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................498 SERVICE CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................502 SERVICE CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................506 SERVICE CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF MERGE / DIVIDE SOLENOID).......................................510 SERVICE CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................514 SERVICE CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................518 SERVICE CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)............................................522 SERVICE CODE IN ELECTRICAL SYSTEM [E218] (DISCONNECTION OF S-NET SIGNAL)..................................................526 SERVICE CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................528 SERVICE CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................529 SERVICE CODE IN ELECTRICAL SYSTEM [E224] (ABNORMALITY IN F PUMP PRESSURE SENSOR)..........................................530 SERVICE CODE IN ELECTRICAL SYSTEM [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR)..........................................532 SERVICE CODE IN ELECTRICAL SYSTEM [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)....................................534 SERVICE CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................536 SERVICE CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................537 SERVICE CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................538 SERVICE CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................540 SERVICE CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................542 SERVICE CODE IN ELECTRICAL SYSTEM [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................544 SERVICE CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY)....545 SERVICE CODE IN ELECTRICAL SYSTEM [E256] (INCORRECT NONVOLATILE MEMORY DATA)..............................................546 SERVICE CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................547 SERVICE CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FULE DIAL).......................................................549 SERVICE CODE IN ELECTRICAL SYSTEM [E315] (SHORT-CIRCUITING IN BATTERY RELAY)..............................................551 SERVICE CODE IN ELECTRICAL SYSTEM [E316] (STEP-OUT IN GOVERNOR MOTOR).....................................................553 SERVICE CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................554 SERVICE CODE IN ELECTRICAL SYSTEM [E318] (SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B).........................556 SERVICE CODE IN ELECTRICAL SYSTEM [E501] ("MODEL SELECTION" FUNCTION NOT PROVIDED YET)....................................558 SERVICE CODE IN ELECTRICAL SYSTEM [E502] (MODEL SELECTING SIGNAL FAULT)...................................................559 FAILURE CODE IN MECHANICAL SYSTEM [A000N1] (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLE).....................................560 FAILURE CODE IN MECHANICAL SYSTEM [A000N2] (OUT-OF-RATE ENGINE ROTATION AT LOW IDLE)......................................560 FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIR CLEANER CLOGGING).........................................................561 FAILURE CODE IN MECHANICAL SYSTEM [ABOOKE] (ABNORMALLY LOWERED CHARGING VOLTAGE)..........................................562 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ABNORMALLY LOWERED ENGINE OIL PRESSURE).......................................565 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ABNORMALLY LOWERED ENGINE OIL LEVEL)..........................................566 FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENGINE COOLANT OVERHEATING)...................................................567 FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ABNORMALLY LOWERED RADIATOR COOLANT LEVEL)....................................568 FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDRAULIC OIL OVERHEATING)....................................................569 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................570 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................571 BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE.............................................................................572 E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)........................................................................573 E-2 ENGINE STOPS WHILE IN OPERATION.......................................................................................577 E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING........................................................................578 E-4 ENGINE DOES NOT STOP..................................................................................................581 E-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................584 E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK..............................................................................585 E-7 PREHEATER DOES NOT WORK...............................................................................................586 E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE......................................................................588 E-9 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK.....................................................................590 E-10 NO DISPLAY IN MONITOR PANEL AT ALL ..................................................................................591 E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING..........................................................................592 E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL..............................................................592 E-13 FULE LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING........................................................593 E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.........................................................594 E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...........................................................595 E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY................................................................................596 E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY........................................................................597 E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS..............................................................599 E-19 WINDSHIELD WIPER DOES NOT WORK.......................................................................................600 E-20 ALARMING BUZZER CANNOT BE CANCELLED..................................................................................602 E-21 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................603 E-22 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................604 E-23 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................605 E-24 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................606 E-25 "BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................607 E-26 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................608 E-27 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...............................................................609 E-28 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION .............................................................611 E-29 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................613 E-30 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.............................................................615 E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM...........................................................................617 E-32 TRAVEL ALARM DOES NOT SOUND..........................................................................................629 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...................................................................630 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS.........................................................................631 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................633 H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW....................................................634 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...........................................................................635 H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE ..............................................................................636 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP....................................................................636 H-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................637 H-6 FINE CONTROL MODE DOES NOT FUNCTION...................................................................................637 H-7 BOOM MOVES SLOWLY OR LACKS POWER......................................................................................638 H-8 ARM MOVES SLOWLY OR LACKS POWER.......................................................................................639 H-9 BUCKET MOVES SLOWLY OR LACKS POWER....................................................................................640 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION.................................................................640 H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT....................................................................641 H-12 WORK EQUIPMENT HAS BIG TIME LAG .....................................................................................642 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT.............................................................642 H-14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE.........................................................................642 H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGE LOAD MOVES SLOWLY...................................................643 H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...................................................................643 H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY........................................................................643 H-18 MACHINE SWERVES IN TRAVEL............................................................................................644 H-19 MACHINE TRAVELS SLOWLY...............................................................................................645 H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER......................................................................646 H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...............................................................647 H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)..........................................................................648 H-23 MACHINE DOES NOT SWING...............................................................................................649 H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...................................................................650 H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................651 H-26 THERE IS BIG SHOCK WHEN STOPPING SWING...............................................................................652 H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...............................................................652 H-28 SWING NATURAL DRIFT IS TOO BIG.......................................................................................653 TROUBLESHOOTING OF ENGINE (S-MODE)............................................................................................654 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................655 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................659 S-2 ENGINE DOES NOT START.................................................................................................661 (1) ENGINE DOES NOT TURN..............................................................................................661 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..........................................662 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).........................................663 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................664 S-4 ENGIEN STOPS DURING OPERATIONS ......................................................................................665 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..............................................................................666 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................667 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................668 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...............................................................669 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................670 S-10 FUEL CONSUMPTION IS EXCESSIVE .......................................................................................671 S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN................................................672 S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)................................................................673 S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)...............................................................................674 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................675 S-15 ABNORMAL NOISE IS MADE...............................................................................................676 S-16 VIBRATION IS EXCESSIVE...............................................................................................677 30 DISASSEMBLY AND ASSEMBLY...........................................................................................................678 HOW TO READ THIS MANUAL...........................................................................................................680 COATING MATERIALS LIST............................................................................................................682 SPECIAL TOOL LIST.................................................................................................................685 SKETCHES OF SPECIAL TOOLS.........................................................................................................689 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY...............................................................................693 REMOVAL.......................................................................................................................693 INSTALLATION..................................................................................................................693 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY..........................................................................694 SPECIAL TOOLS.................................................................................................................694 REMOVAL.......................................................................................................................694 INSTALLATION..................................................................................................................696 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.....................................................................................698 SPECIAL TOOLS.................................................................................................................698 REMOVAL.......................................................................................................................698 INSTALLATION..................................................................................................................698 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL......................................................................................700 REMOVAL.......................................................................................................................700 INSTALLATION..................................................................................................................701 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................702 SPECIAL TOOLS.................................................................................................................702 REMOVAL.......................................................................................................................702 INSTALLATION..................................................................................................................705 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY.....................................................................................708 REMOVAL.......................................................................................................................708 INSTALLATION..................................................................................................................709 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.........................................................................710 REMOVAL.......................................................................................................................710 INSTALLATION..................................................................................................................711 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES..................................................................712 SPECIAL TOOLS.................................................................................................................712 REMOVAL.......................................................................................................................712 INSTALLATION..................................................................................................................716 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY..................................................................................718 REMOVAL.......................................................................................................................718 INSTALLATION..................................................................................................................718 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..................................................................................719 SPECIAL TOOLS.................................................................................................................719 DISASSEMBLY...................................................................................................................719 ASSEMBLY......................................................................................................................721 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................726 REMOVAL.......................................................................................................................726 INSTALLATION..................................................................................................................726 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................728 SPECIAL TOOLS.................................................................................................................728 DISASSEMBLY...................................................................................................................728 ASSEMBLY......................................................................................................................730 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................735 SPECIAL TOOLS.................................................................................................................735 DISASSEMBLY...................................................................................................................735 ASSEMBLY......................................................................................................................737 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY...............................................................................749 SPECIAL TOOLS.................................................................................................................749 ASSEMBLY......................................................................................................................749 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.................................................................................750 SPECIAL TOOLS.................................................................................................................750 ASSEMBLY......................................................................................................................750 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY........................................................................................751 SPECIAL TOOLS.................................................................................................................751 DISASSEMBLY...................................................................................................................751 ASSEMBLY......................................................................................................................752 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................................................................................754 SPECIAL TOOLS.................................................................................................................754 DISASSEMBLY...................................................................................................................754 ASSEMBLY......................................................................................................................755 REMOVAL AND INSTALLATION OF SPROCKET..............................................................................................756 REMOVAL.......................................................................................................................756 INSTALLATION..................................................................................................................756 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY...................................................................................757 SPECIAL TOOLS.................................................................................................................757 REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON)...........................................................................757 INSTALLATION..................................................................................................................758 REMOVAL AND EXPANSION OF ROAD LINERS..........................................................................................759 INSTALLATION OF ROAD LINERS...................................................................................................760 REMOVAL AND INSTALLATION OF SWING CIRCUIT ASSEMBLY................................................................................761 REMOVAL.......................................................................................................................761 INSTALLATION..................................................................................................................761 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY..............................................................................762 REMOVAL.......................................................................................................................762 INSTALLATION..................................................................................................................763 REMOVAL AND INSTALLATION OF CENTER SWIVEL JIONT ASSEMBLY..........................................................................764 REMOVAL.......................................................................................................................764 INSTALLATION..................................................................................................................765 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY..........................................................................766 SPECIAL TOOLS.................................................................................................................766 DISASSEMBLY...................................................................................................................766 ASSEMBLY......................................................................................................................766 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...............................................................................767 REMOVAL.......................................................................................................................767 INSTALLATION..................................................................................................................768 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY................................................................................769 REMOVAL.......................................................................................................................769 INSTALLATION..................................................................................................................771 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY................................................................................772 SPECIAL TOOLS.................................................................................................................772 ASSEMBLY......................................................................................................................773 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...............................................................................775 SPECIAL TOOLS.................................................................................................................775 REMOVAL.......................................................................................................................775 INSTALLATION..................................................................................................................777 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT................................................................778 SPECIAL TOOLS.................................................................................................................778 REMOVAL.......................................................................................................................778 INSTALLATION..................................................................................................................778 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................779 DISASSEMBLY...................................................................................................................779 ASSEMBLY......................................................................................................................779 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................781 DISASSEMBLY...................................................................................................................781 ASSEMBLY......................................................................................................................781 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.............................................................................783 SPECIAL TOOLS.................................................................................................................783 ASSEMBLY......................................................................................................................783 DISASSEMBLY...................................................................................................................783 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.............................................................................785 DISASSEMBLY...................................................................................................................785 SPECIAL TOOLS.................................................................................................................785 ASSEMBLY......................................................................................................................785 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...........................................................................787 SPECIAL TOOLS.................................................................................................................787 DISASSEMBLY...................................................................................................................787 ASSEMBLY......................................................................................................................789 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...............................................................................793 SPECIAL TOOLS.................................................................................................................793 REMOVAL.......................................................................................................................793 INSTALLATION..................................................................................................................794 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.........................................................................796 REMOVAL.......................................................................................................................796 INSTALLATION..................................................................................................................798 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.........................................................................799 REMOVAL.......................................................................................................................799 INSTALLATION..................................................................................................................800 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY................................................................................801 REMOVAL.......................................................................................................................801 INSTALLATION..................................................................................................................801 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...............................................................................802 REMOVAL.......................................................................................................................802 INSTALLATION..................................................................................................................803 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...............................................................................804 REMOVAL.......................................................................................................................804 INSTALLATION..................................................................................................................806 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS).....................................................................807 SPECIAL TOOLS.................................................................................................................808 REMOVAL.......................................................................................................................808 INSTALLATION..................................................................................................................809 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.................................................................................817 REMOVAL.......................................................................................................................817 INSTALLATION..................................................................................................................819 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY......................................................................................822 REMOVAL.......................................................................................................................822 INSTALLATION..................................................................................................................822 REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY....................................................................823 REMOVAL.......................................................................................................................823 INSTALLATION..................................................................................................................823 90 OTHERS.............................................................................................................................824 HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................825 PC200-7, PC200LC-7............................................................................................................825 PC220-7, PC220LC-7............................................................................................................826 ELECTRICAL CIRCUIT DIAGRAM (PC200-7, PC200LC-7 : SERIAL NO. 200001-250000 PC220-7, PC220LC-7 : SERIAL NO. 60001-65000)............827 FOR MULTI MONITOR.............................................................................................................827 FOR 7-SEGMENT MONITOR.........................................................................................................831 ELECTRICAL CIRCUIT DIAGRAM (PC200-7, PC200LC-7 : SERIAL NO. 250001 AND UP, PC220-7, PC220LC-7 : SERIAL NO. 65001 AND UP)..........835 ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER....................................................................................839
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